Indirect Coal Liquefaction

Transcription

1 Indirect Coal Liquefaction Shell Coal Gasification with Fischer-Tropsch Synthesis Karsten Radtke (speaker), Uhde GmbH (Germany) John W. Rich Jr., Robert Hoppe, WMPI, Inc. (USA)

2 ThyssenKrupp Group Workforce: 185,000 Sales: 41 bn ID10 2 Steel Automotive Elevator Technologies Services Carbon Steel Stainless Steel Special Materials Body & Chassis (North America) Body & Chassis (Europe/ Asia/Pacific/ Latin America) Powertrain (Global) Metal Cutting Plant Technology Marine Systems Mechanical Engineering Materials Services Europe Materials Services North America Industrial Services Special Products Transrapid Steel Capital goods Services Uhde

3 WMPI Project Waste Coal to Ultra Clean Liquid Fuels Integration of three major blocks: 1. Gasification of Waste Coal to Produce Synthesis Gas 2. Conversion of Synthesis Gas using Fischer-Tropsch Technology to Liquid Fuels 3. Combustion of Tail Gas to produce Electric Power and Steam

4 The Team WMPI, Inc. Waste Management and Processors Inc. (Owner) Nexant (Owner s Engineer) Shell Global Solutions (Licensor) Sasol Technology / ChevronTexaco (Licensor) Uhde (Engineering and turnkey contractor) Black & Veatch (Uhde s U.S. gasification alliance partner)

5 100,000,000 US-Dollars (granted) U.S. Department of Energy Clean Coal Power Initiative (CCPI) National U.S. Energy Bill WMPI Ultra Clean Fuels Indirect Coal Liquefaction Plant 5,000 bpd Diverse Support Mechanisms (pending)

6 Shell SCGP Koppers-Totzek High-Temperature Winkler (HTW) Shell SGP Gasification Portfolio Application defines Process

7 Uhde s Gasification Portfolio Process Winkler / HTW Koppers- Totzek Shell SCGP (Prenflo) Shell SGP Principle Fluidized Bed Entrained Flow Entrained Flow Entrained Flow Temp C C C C Pressure < 30 bar atm bar bar Feeding Dry Solid Dry Solid Dry Solid Liquid, Gas First Plants 1926 (Winkler) (Leuna) 1950 (Tippy Oy) 1979 (Hamburg) Uhde s 1st: 1964 (Belgium) Plants (Examples) Wachtberg Berrenrath Oulu Wesseling Talkha New Delhi Modderfontein Murphy Hill Fürstenhausen Houston Buggenum Puertollano Pernis Leuna Haldia Nangal References 40 Plants 77 Plants 5 Plants 168 Plants

8 Development of Uhde s Gasification Portfolio K-T TGP TCGP SGP SCGP Prenflo HTW

9 Coal/Biomass gasification for power generation Shell Coal Gasification IGCC (253 MWe) Buggenum, The Netherlands

10 Coal/Petcoke/Biomass gasification for power generation IGCC Puertollano 318 MWel, net (feedstock: petcoke / coal)

11 Coal / Waste Gasification for liquid fuels (methanol, gasoline)

12 Uhde s GTL/BTL/CTL Activities WMPI - 5,000 bpd, SCPG + FT Synthesis: Uhde is selected EPC Contractor DKRW - 30,000 bpd, SCGP + FT Synthesis: Uhde is selected EPC Contractor 4 further U.S. projects (confidential) bpd each, SCGP + FT Synthesis: Uhde is selected EPC Contractor German/Chinese Sustainable Fuel Partnership (GCSFP): => (German/Chinese governments, Shell, VW, BMW, DaimlerChrysler, BP, Bosch, Uhde) - concepts include CTL, BTL, Biodiesel, Hydrogen) BTL Pilot Plant, IEC Freiberg: Engineering phase for modified HTW (PHTW) based pilot plant - Methanol to Synfuel (MtS) Syntroleum: GTL Sweet Water Project, Basic Engineering UK Wesseling Methanol-to-Gasoline (Mobil MTG) plant at : => Brown Coal gasification to Gasoline (HTW + MTG) HTW Gasification for biomass (peat) to methanol, Oulo, Finland Direct Coal Liquefaction development (1970 s) - not commercialised

13 Plant Site: Gilberton, Pennsylvania, U.S.A.

14 Project Black Box Coal (Culm) Flux Air WMPI Coal Liquefaction Plant Ultra Clean Fuels Power Slag Sulfur Fly Ash

15 Fischer Tropsch / Coal to Liquids Hydrogen Coal PSA Gas Turbine Steam Syst. Power Steam Gasification CO-Shift Acid Gas Removal Internal Recycle FT-Reaction Chemistry: CO + 2 H 2 -CH H 2 O; H = kj/mol Fischer Tropsch Heavy Ends Recovery FT WAX FT Condensate Water Treatment Effluent Water Product Work-up Diesel Naphtha

16 Fischer Tropsch - Products 1.) Ultra Clean Fuels (Naphtha, Diesel, Jet) - High Cetane (> 70) - Free of Sulfur (< 1ppm) - Free of Aromatics (< 1ppm) and heavy metals 2.) Specialties - Lube Oils - Paraffins (e.g. for detergents, solvents etc.) - Paraffin Waxes (e.g. for candles, colours, pharmaceuticals etc.)

17 Biomass (e.g. 30 %) Coal Feedstock Preparation Milling Gasification Coal + Biomass => Ultra Clean Diesel Blend (e.g. 70 %) Syngas Replacement of Natural Gas with Coal/Biomass derived Syngas Natural XGas Fischer- Tropsch Synthesis Refinery Crude Oil Derived Diesel (e.g. 90 %) Diesel Blending F-T Diesel (e.g. 10 %) Merchant ultra clean Biomass/Coal derived Diesel Ultra Clean Fuels Production Feedstock: Coal + Biomass

18 Process Units (Simplified Block Flow diagram)

19 Solids Processing ¾ carbon Homogeneously mixed Feedstock 28 mesh reject (Rock) Fluxant Petcoke Coal Dust Raw Culm Raw Tailings Culm / Tailings Processing Coal Milling & Drying Gasification Raw gas +10 reject (Rock) ¾ reject (Rock) 28 mesh carbon Slag fines Slag Fly ash

20 COAL/PETCOKE FLY ASH RECIRC. QUENCH GAS MILLING/DRYING GASIFIER 900 C HP STEAM MP STEAM Coal Feeding 1600 C DRY SOLIDS REMOVAL WET SCRUBBING GAS TREATING CLEAN SYNGAS Slag FLY ASH SYSTEM WATER TREATMENT FLY ASH TO MILLING AND DRYING SALTS SULPHUR Shell SCGP Process Line-Up

21 Erection of the Coal/Petcoke Gasifier in Puertollano, Spain Shell Coal Gasification Process (SCGP) Solid Feedstocks

22 Membrane Wall protected by the slag layer molten slag solidified slag Gasification Chamber > 1500 C Water Tube (membrane wall) molten slag flows downwards BFW, bar Shell Coal/Coke Gasification SCGP

23 . Membrane wall for gasifier (test piece)

24 IGCC Puertollano 318 MWel, net (feedstock: petcoke / coal)

25 Preliminary Plot Plan

26 Project Benefits Economical Benefits 1. Coal Production & Revitalization 2. Creating Jobs: Construction and Operating 3. Energy Diversification & Independence Environmental Benefits 1. Waste Utilization 2. Ultra Clean Fuels 3. Extreme low emissions from production and fuel use

27 Project Execution Structure WMPI Lump Sum Turn Key Contract Uhde / Black & Veatch Krupp Uhde Project Directorate Single Single Point Point Responsibility Responsibility Gasification Island Syngas to Liquids Unit Downstream Units Utilities Utilities Power Block ASU Shell / Uhde Basic Engineering Sasol / ChevTx Basic Engineering Licensors Basic Engineering B&V Basic Engineering B&V Basic Engineering ASU Vendor Package Unit Uhde & B&V - Task Force Detail Engineering, Procurement, Supervision, Commissioning B&V - Civil and Erection

28 Summary Estimated net plant efficiency: 42% Economical & Marketable Fuels & Power Advanced Technologies for Future Needs Demonstrate Operability, Reliability

29 Conclusion The WMPI Project: Will be America s first Coal-to-Liquids plant in commercial size and act as demonstration plant. => Establishment of sustainable CTL market in the U.S. and worldwide.